2nd Gen Non-Engine/Transmission T-Case leaking

[Junior]

My Tcase is leaking and heard to replace the seal and a bushing supposedly on the inside. Seeing if anyone has had experiance. How much of a pain is it to replace the bushing. It leaking at the point were driveshaft goes in.



any info would be appreciated

 

[Crowhurst]

Junior, my truck leaked at the same point, and changing just the seal fixed it. My reading on this forum confirms that's what is generally done.

Nick.

 

[Bobcat698]

How hard is it to replace? My tcase is damp by where the output shaft is.

 

[Dl5treez]

Drop the driveshaft, pull the old seal out, press the new one in.



The extension housing is aluminum and the seal is in there pretty tight, so BE CAREFUL if you use a hook-type seal puller---easy to cut a groove in the housing.



I added a thin bead of sealant to the outer steel edge of the new seal before installing.

 

[Crowhurst]

You might like to go to this thread for detailed advice https://www.turbodieselregister.com/forums/showthread.php?t=130244

The thread contains a link to another thread which describes the various part numbers for the various types of transfer case (231,241, HD etc) It's very easy to be supplied the wrong seal. It took me three tries to get the correct one. If you have 4 wheel drive, and hence a centre bearing on the rear propshaft, I've found it a great help to reinstall the 4 carrier bolts with the flag nuts on top of the crossbar. As built, the flags are easily accessible, but the rear two bolt heads are awkward to get at. How weird is that? Good luck with the job. While you have the prop shaft off, it would be an ideal chance to replace the circlip in the extension housing with a Gilly's transfer case saver. This could save an expensive breakdown. I bought and fitted one last year at a cost of $48 from Drivetrain Specialists, tel. 702 876 3100.

Nick.